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7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 112
Carbon Fibre in Mass Automotive ApplicationsChallenges and Drivers for composites
Robert Crow CEng MIMMMaterials Innovation Manager
Franco-British Symposium on Composite Materials 28th April
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 212
2CONFIDENTIAL
Franco-British Symposium
Agenda
bull Drivers for Automotive Weight Saving
bull JLR Light Weighting Strategy
bull Composites Challenges ndash Cost and Sustainability
bull Innovate UK Varcity Project
bull Summary
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 312
3CONFIDENTIAL
Franco-British Symposium
The CO2 Challenge
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 412
4CONFIDENTIAL
Franco-British Symposium
JLR Lightweighting Strategy
120 kg
TDV6powertrainsystems
300 kg
Aluminiumbody andclosures
smc tailgatealuminiumsuspension
and subframes
2580 kg
PreviousRange Rover
2160 kg
420 kg
All-NewRange Rover
Target 400+ kg weight save
Reduced weight improvesvehicle dynamics agileresponsive handling onand off road
Aluminium and lightweightmaterials reduce overallcarbon footprint
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 512
5CONFIDENTIAL
Franco-British Symposium
CFRP - Historical Perspective
983112983145983155983156983151983154983145983139983137983148983148983161 983148983145983156983156983148983141 983144983137983155 983138983141983141983150 983140983151983150983141 983156983151 983154983141983140983157983139983141 983107983110983122983120 983123983161983155983156983141983149 983139983151983155983156 983151983150 983117983151983156983151983154 983154983137983139983145983150983143 983078 983123983157983152983141983154983139983137983154983155 983140983157983141
983156983151 983148983151983159 983152983154983151983140983157983139983156983145983151983150 983158983151983148983157983149983141983155 983078 983141983160983151983156983145983139 983139983151983149983152983148983141983160983145983156983161 983151983142 983152983154983151983140983157983139983156983155 983157983155983141983140 983156983151 983149983137983150983157983142983137983139983156983157983154983141 983152983137983154983156983155
983110983151983139983157983155 983151983150 983120983141983154983142983151983154983149983137983150983139983141 991251 983150983151983156 983107983119983090 983154983141983140983157983139983156983145983151983150
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 212
2CONFIDENTIAL
Franco-British Symposium
Agenda
bull Drivers for Automotive Weight Saving
bull JLR Light Weighting Strategy
bull Composites Challenges ndash Cost and Sustainability
bull Innovate UK Varcity Project
bull Summary
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 312
3CONFIDENTIAL
Franco-British Symposium
The CO2 Challenge
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 412
4CONFIDENTIAL
Franco-British Symposium
JLR Lightweighting Strategy
120 kg
TDV6powertrainsystems
300 kg
Aluminiumbody andclosures
smc tailgatealuminiumsuspension
and subframes
2580 kg
PreviousRange Rover
2160 kg
420 kg
All-NewRange Rover
Target 400+ kg weight save
Reduced weight improvesvehicle dynamics agileresponsive handling onand off road
Aluminium and lightweightmaterials reduce overallcarbon footprint
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 512
5CONFIDENTIAL
Franco-British Symposium
CFRP - Historical Perspective
983112983145983155983156983151983154983145983139983137983148983148983161 983148983145983156983156983148983141 983144983137983155 983138983141983141983150 983140983151983150983141 983156983151 983154983141983140983157983139983141 983107983110983122983120 983123983161983155983156983141983149 983139983151983155983156 983151983150 983117983151983156983151983154 983154983137983139983145983150983143 983078 983123983157983152983141983154983139983137983154983155 983140983157983141
983156983151 983148983151983159 983152983154983151983140983157983139983156983145983151983150 983158983151983148983157983149983141983155 983078 983141983160983151983156983145983139 983139983151983149983152983148983141983160983145983156983161 983151983142 983152983154983151983140983157983139983156983155 983157983155983141983140 983156983151 983149983137983150983157983142983137983139983156983157983154983141 983152983137983154983156983155
983110983151983139983157983155 983151983150 983120983141983154983142983151983154983149983137983150983139983141 991251 983150983151983156 983107983119983090 983154983141983140983157983139983156983145983151983150
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 312
3CONFIDENTIAL
Franco-British Symposium
The CO2 Challenge
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 412
4CONFIDENTIAL
Franco-British Symposium
JLR Lightweighting Strategy
120 kg
TDV6powertrainsystems
300 kg
Aluminiumbody andclosures
smc tailgatealuminiumsuspension
and subframes
2580 kg
PreviousRange Rover
2160 kg
420 kg
All-NewRange Rover
Target 400+ kg weight save
Reduced weight improvesvehicle dynamics agileresponsive handling onand off road
Aluminium and lightweightmaterials reduce overallcarbon footprint
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 512
5CONFIDENTIAL
Franco-British Symposium
CFRP - Historical Perspective
983112983145983155983156983151983154983145983139983137983148983148983161 983148983145983156983156983148983141 983144983137983155 983138983141983141983150 983140983151983150983141 983156983151 983154983141983140983157983139983141 983107983110983122983120 983123983161983155983156983141983149 983139983151983155983156 983151983150 983117983151983156983151983154 983154983137983139983145983150983143 983078 983123983157983152983141983154983139983137983154983155 983140983157983141
983156983151 983148983151983159 983152983154983151983140983157983139983156983145983151983150 983158983151983148983157983149983141983155 983078 983141983160983151983156983145983139 983139983151983149983152983148983141983160983145983156983161 983151983142 983152983154983151983140983157983139983156983155 983157983155983141983140 983156983151 983149983137983150983157983142983137983139983156983157983154983141 983152983137983154983156983155
983110983151983139983157983155 983151983150 983120983141983154983142983151983154983149983137983150983139983141 991251 983150983151983156 983107983119983090 983154983141983140983157983139983156983145983151983150
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 412
4CONFIDENTIAL
Franco-British Symposium
JLR Lightweighting Strategy
120 kg
TDV6powertrainsystems
300 kg
Aluminiumbody andclosures
smc tailgatealuminiumsuspension
and subframes
2580 kg
PreviousRange Rover
2160 kg
420 kg
All-NewRange Rover
Target 400+ kg weight save
Reduced weight improvesvehicle dynamics agileresponsive handling onand off road
Aluminium and lightweightmaterials reduce overallcarbon footprint
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 512
5CONFIDENTIAL
Franco-British Symposium
CFRP - Historical Perspective
983112983145983155983156983151983154983145983139983137983148983148983161 983148983145983156983156983148983141 983144983137983155 983138983141983141983150 983140983151983150983141 983156983151 983154983141983140983157983139983141 983107983110983122983120 983123983161983155983156983141983149 983139983151983155983156 983151983150 983117983151983156983151983154 983154983137983139983145983150983143 983078 983123983157983152983141983154983139983137983154983155 983140983157983141
983156983151 983148983151983159 983152983154983151983140983157983139983156983145983151983150 983158983151983148983157983149983141983155 983078 983141983160983151983156983145983139 983139983151983149983152983148983141983160983145983156983161 983151983142 983152983154983151983140983157983139983156983155 983157983155983141983140 983156983151 983149983137983150983157983142983137983139983156983157983154983141 983152983137983154983156983155
983110983151983139983157983155 983151983150 983120983141983154983142983151983154983149983137983150983139983141 991251 983150983151983156 983107983119983090 983154983141983140983157983139983156983145983151983150
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 512
5CONFIDENTIAL
Franco-British Symposium
CFRP - Historical Perspective
983112983145983155983156983151983154983145983139983137983148983148983161 983148983145983156983156983148983141 983144983137983155 983138983141983141983150 983140983151983150983141 983156983151 983154983141983140983157983139983141 983107983110983122983120 983123983161983155983156983141983149 983139983151983155983156 983151983150 983117983151983156983151983154 983154983137983139983145983150983143 983078 983123983157983152983141983154983139983137983154983155 983140983157983141
983156983151 983148983151983159 983152983154983151983140983157983139983156983145983151983150 983158983151983148983157983149983141983155 983078 983141983160983151983156983145983139 983139983151983149983152983148983141983160983145983156983161 983151983142 983152983154983151983140983157983139983156983155 983157983155983141983140 983156983151 983149983137983150983157983142983137983139983156983157983154983141 983152983137983154983156983155
983110983151983139983157983155 983151983150 983120983141983154983142983151983154983149983137983150983139983141 991251 983150983151983156 983107983119983090 983154983141983140983157983139983156983145983151983150
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 612
6CONFIDENTIAL
Franco-British Symposium
Weight save vs cost increase
bull The key driver is weight save due to the increase in specific strengthand stiffness that carbon fibre composites offer
bull The key enabler to using carbon fibre is lower cost ndash high costgenerally makes carbon fibre components prohibitive unlessadditional revenue can be made (eg cosmetic parts)
Steel Aluminium Carbon
bull 40 weight save
bull X2 cost
bull 30 weight save
bull X10 cost
bull 60 weight savebull X20 cost
Need tofurtherreduce
compositecost
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 712
7CONFIDENTIAL
Franco-British Symposium
Cost vs annual volume
To enable CFRP structures to be used is mass-produced vehicles costs
need to be further reduced
0
5
10
15
20
25
30
35
0 -1K 1K - 10K 10K - 100K
C o
s t
( pound 1 0 0 0 )
Annual volume
Material cost
Process cost
Post process
Target lt pound3k
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 812
8CONFIDENTIAL
Franco-British Symposium
Environment
bull Lower in-use CO2 the most significant of Life Cycle Analysis (LCA)
bull The light-weighting possibilities support the electric hybrid vehiclesneed for super lightweight structures
bull However overall LCA and End of Life
Vehicle (ELV) impact not as favourableas current BIW construction JLR use
up to 50 recycled aluminium which is
easily recycled with current infrastructure
and is infinitely recyclable
bull Scrap rates of (some) manufacturing processes too high ndash pre-preg off
cuts are challenging to up-cycle
bull Alternative Solutions - Natural fibres Thermoplastics Glass
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 912
9CONFIDENTIAL
Franco-British Symposium
Varcity
Varcity Vehicle ARchitectures CITY Cars
bull 36 Month Innovate UK Funded project total value pound17million
bull Premium city car for 2020
bull Sustainable and economically viable proposition for volume productionof Carbon Fibre Reinforced Plastic based composites
bull A major goal of the project is the establishment of leading UK supply
chain comprising the core industry partners
bull The project also acts as a catalyst to stimulate the science engineeringand technology base to support the CO2 and sustainability challengesfacing the UKs automotive industry
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1012
10CONFIDENTIAL
Varcity Vehicle ARchitectures CITY Cars
Franco-British Symposium
Varcity
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1112
11CONFIDENTIAL
Franco-British Symposium
Summary
Technical
Performanceand weight
Business
Profitability
andinvestment
Market
Volume and
price
ldquoThe right material for theright partrdquo
The aim of all JLR material
choices is to develop product
propositions that balance thetechnical business and market
equations whilst delivering CO2
offset for the JLR fleet average
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
7232019 Carbon Fibre Applications in Mass-produced Automotive Structures
httpslidepdfcomreaderfullcarbon-fibre-applications-in-mass-produced-automotive-structures 1212
12CONFIDENTIAL
Questions
wwwjaguarlandrovercareerscom
Thank you
Robert Crowrcrow4jaguarlandrovercom
